High thermal resistance and permeance insulation material

ABSTRACT

A low-emittance material having improved energy efficiency protection against air infiltration and moisture build-up in buildings is disclosed. The aforementioned low-emittance material utilizes existing framing openings or without increasing the wall profile of a building. The present invention provides a low-emittance material which may be implemented on traditional 2×4 framing having R-15 mass insulation material within existing or newly constructed framing cavities. The material of the present invention also meets requirements for serving as a water resistive barrier as defined by ICC AC38.

PRIORITY

The present application is a continuation of application Ser. No.13,107,568, filed on May 13, 2011, which claims priority to provisionalpatent application entitled, “LOW-E HOUSEWRAP,” filed on May 21, 2010,and assigned U.S. Application Ser. No. 61/346,916. The contents of theseapplications are incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to building structure materials,and more specifically to an infiltration barrier used in buildingconstruction to improve energy efficiency and to protect against airinfiltration and moisture build-up in buildings.

2. Description of Related Art

In order to improve the energy efficiency of new and existing buildings,it has been common practice in building new structures, and in residingold structures, to cover the exterior wall sheathing with aninfiltration barrier, for example, prior to installation of a coveringmaterial such as siding. One such infiltration barrier is a high densitypolyethylene fiber sheeting. While infiltration barriers cut down ondrafts and thereby convective heat loss, they provide little othercontribution to the energy efficiency of the structure.

In addition to addressing energy efficiencies of new and existingbuildings, moisture concerns can be one of the worst enemies of home orbuilding construction. Water or moisture or humid air infiltration ifallowed to penetrate behind siding or brick can saturate the wood of abuilding structure, thereby creating an environment that encouragesmildew or rot. A weather resistant barrier has for many years beenapplied to the wood studs of buildings and homes in order to resist themoisture or water generated by weather. Such material is typicallyflexible and in a film or sheet form. Typically, this weather resistantbarrier or “house wrap” is applied to the wooden stud frame before theapplication of a final siding or veneer (e.g. brick, metal, paintedwood). Many such “wrap” products are commercially available such as, forexample: Dupont Tyvek®, Typar®. Housewrap (www.typarhousewrap.com), andBarricade®. building wrap (www.ludlowcp.com).

In 2010 the International Energy Conservation Code (IECC) andInternational Residential Code (IRC) increased the thermal performancerequirements for residential walls. Both of these standards seek toimprove thermal performance and reduce energy needs per dwelling. As ofJanuary 2010 the U-value requirement for geographical area or zones 5-8is 0.057; the reciprocal R-value for wall systems is R-20. The U-factoris the inverse, or reciprocal, of the total R-Value, i.e.:U-factor=1/Total R-Value. The R-Value is the thermal resistance to heatflow. A larger R-Value means that the material has greater thermalresistance and more insulating ability as compared to a smaller R-Value.Such R-Values can be added together. For instance, for homogeneousassemblies, the total R-Value of an insulation assembly is the sum ofthe R-Value of each layer of insulation. These layers may includesheathing and finishes, the insulation itself, air films andweatherproofing elements.

In order to meet the new building requirements, builders have employedadditional building techniques such as altering construction of framedopenings. For example, typically, builders have constructed walls on 2×4framing. However, due to the revised requirements, builders are alteringbuilding designs by constructing walls on 2×6 framing and inserting, forexample, R-20 mass insulation within the respective wall cavity in orderto meet the energy/code regulations mandated within the buildingindustry. These techniques, however, increase construction costs becauseof the added and more expensive construction materials. In addition, theincreased size of framing also produces a loss in living space.Nevertheless, many builders have simply accepted the added cost and lossof living space created by the newly implemented thermal code changes.

Accordingly, a need exists for providing a protective wrap that improvesenergy efficiency and protection against air infiltration and moisturebuild-up in buildings while satisfying newly implemented industry-wideenergy/code regulations. There is also a need for employing a protectivewrap which meets or exceeds the newly implemented code requirements onexisting framing structures or openings and/or without increasing thewall profile of a building.

SUMMARY OF THE INVENTION

The present invention provides a low-emittance housewrap material whichmay be implemented on traditional 2×4 framing having R-15 massinsulation material within existing or newly constructed framingcavities. The material of the present invention also meets requirementsfor serving as a water resistive barrier as defined by The InternationalCode Council's (ICC) codes and standards used to construct residentialand commercial buildings, including homes and schools (e.g., ICC AC38).Thus, by not increasing the wall profile in the attempt to meet newindustry standards, the builder does not have to perform additionaltechniques or provide additional expenses for constructing framedopenings.

Still other aspects, features and advantages of the present inventionare readily apparent from the following detailed description, simply byillustrating a number of exemplary embodiments and implementations,including the best mode contemplated for carrying out the presentinvention. The present invention also is capable of other and differentembodiments, and its several details can be modified in variousrespects, all without departing from the spirit and scope of the presentinvention. Accordingly, the drawings and descriptions are to be regardedas illustrative in nature, and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood more fully from the detaileddescription given below and from the accompanying drawings of variousembodiments of the invention, which, however, should not be taken tolimit the invention to the specific embodiments, but are for explanationand understanding only.

FIG. 1 provides a top view of a low-emittance housewrap materialaccording to an exemplary disclosed embodiment;

FIG. 2 provides a cross-sectional view of a low-emittance housewrapmaterial according to an exemplary disclosed embodiment;

FIG. 3 provides a cut-away perspective view of a low-emittance housewrapmaterial according to an exemplary disclosed embodiment;

FIG. 4 provides a top view of a low-emittance housewrap materials duringan assembly method according to an exemplary disclosed embodiment;

FIG. 5 provides a perspective view of the low-emittance housewrapmaterials during the assembly method of FIG. 4;

FIG. 6 provides a top view of a low-emittance housewrap materials duringa continued assembly method according to an exemplary disclosedembodiment;

FIG. 7 provides a perspective view of the low-emittance housewrapmaterials during the assembly method of FIG. 6;

FIG. 8 provides a top view of low-emittance housewrap materials afterassembly according to an exemplary disclosed embodiment;

FIG. 9 provides a bottom view of low-emittance housewrap materials priorto assembly according to an exemplary disclosed embodiment;

FIG. 10 provides a top view of low-emittance housewrap materials duringan assembly method according to an exemplary disclosed embodiment;

FIG. 11 provides a bottom view of low-emittance housewrap materialsafter assembly according to an exemplary disclosed embodiment;

FIG. 12 provides an exemplary exterior wall according to an exemplarydisclosed embodiment; and

FIG. 13 provides a low-emittance housewrap material application to theexemplary wall structure of FIG. 12 according to an exemplary disclosedembodiment.

DETAILED DESCRIPTION

A low-emittance housewrap is described. In the following description,for purposes of explanation, numerous specific details are set forth inorder to provide a thorough understanding of the exemplary embodiments.It is apparent to one skilled in the art, however, that the presentinvention can be practiced without these specific details or with anequivalent arrangement.

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, FIG. 1illustrates a top view of low-emittance housewrap materials according toone disclosed embodiment of the present invention. By way of example,two pieces of the low-emittance housewrap materials 10, 12 are shown.Each of the two pieces of low-emittance housewrap materials 10, 12 maycomprise flap portions 14, 16, respectively, at one end thereof. Atanother end the low-emittance housewrap material may include an adhesivestrip 18 such as that provided on low-emittance housewrap material 10.In a preferred embodiment, the top surface 20, 22 of the low-emittancehousewrap materials 10, 12, respectively, is a reflective material suchas a layer of reinforced foil material.

Turning to FIG. 2, a cross-section of the low-emittance housewrapmaterial 12 is shown. The low-emittance housewrap material 12 maycomprise an assembly of product component parts including, for example,a reflective foil material 34, foil reinforcement 26, and a foammaterial 28. In one embodiment, the reflective material may comprise afacing of approximately 99.4% polished aluminum. It is noted that thereflective material may comprise a facing having any suitable amount ofaluminum, for example, greater than about 90%, preferably between about90% and about 99.9%, even more preferably between about 99.0% and about99.9%. The reflective foil material 34 may be nonreinforced on one side.On the other side, the reflective foil material 34 may comprise a foilreinforcement 26 including, for example, a scrim foil reinforcing 30(e.g., see FIG. 3). Scrim is a term known in the art to consist ofcrossed lines of plastics material which serve to strengthen the overallproduct and to prevent stretching damage to the layers. The reflectivefoil material 34 and foil reinforcement 26 may be applied over andbonded to the foam material 28. The scrim foil reinforcing 30 issufficient to provide a tensile strength of approximately 23 pounds perinch width in a machine direction and 25 pounds per inch width in across machine direction on a low-emittance housewrap material testspecimen cut approximately 1″ wide by 9″ long in standard ambient labconditions. The foam material 28 serves as a polyolefin thermal breaksuch as one comprising a closed cell polyethylene foam. In a preferredembodiment, the nominal thickness of the polyolefin thermal break isapproximately ¼″ (0.25″). It is noted that the nominal thickness of thepolyolefin thermal break may be any suitable thickness, for example,greater than about ⅛″ (0.125″) and less than about ⅜″ (0.375″).Thicknesses above about ¼″ are within the scope of the presentinvention. It is noted that a thickness greater than about ¼″ mayrequire use of 2×6 framing instead of the more traditional 2×4 framing.The low-emittance housewrap 12 may also incorporate a self adhereddrainage plane 24 feature as further described below.

Thus, the invention includes a layer of polyethylene foam which servesas a support for the other added component layers. Polyethylene foam orequivalent polypropylene foam may be utilized, both being in thechemical family designated as polyolefins. A thin layer of aluminum foilis bonded indirectly to one or both sides of said foam layer. Thinpolyethylene layers are placed between the aluminum foil and the foamedlayer. The thin polyethylene is bonded to the aluminum foil layer togreatly improve its resistance to tearing. This strengthening featuremeans that the end product has a much wider use than has been known inthe art. A layer of strengthening scrim may be added to further enhancethe product integrity. In practice of the invention, the various layersadjoin one another after being flame or heat roller laminated together.

In certain embodiments and in practice of the invention, both sides ofthe foam layer may be covered with layers as described above. The endproduct may thus appear identical on either side with the aluminum foillayers being externally located. Thus, use and installation issimplified since the product may be used with either side facing outsince both external faces are identical. The resulting bonded layers areeasily rolled, transported and installed without requiring special toolsor environmental precautions which must be taken with many other priorart insulations.

Turning to FIG. 3, the low-emittance housewrap 12 comprises perforations32 sufficiently spaced to ensure that the low-emittance housewrapmaterial does not act as a vapor barrier. In one preferred embodiment,the perforations in the low-emittance housewrap are generated fromperforation system consisting of 1/16″ punchers placed in four holes per1.25 square inch sequence on a collar mechanism. The collar mechanism ismounted to a drive roll assembly for perforation of the low-emittancehousewrap wherein a 1.25 square inch perforation pattern is achieved onthe finished product. A perforation pattern of 1.25 square inch allowslow-emittance housewrap 12 to meet the criteria for perms, water vaportransmission and water resistance while maintaining an effectiveemissivity rating. This is unique and contrary to industry standardswherein in many applications, micro perforations are generated inhousewraps using needles for vapor penetration. However, in suchconvention applications, the micro perforations are susceptible toresealing when exposed to higher temperatures. This affect may trapmoisture and induce undesirable results such as mold and rot. Incontrast, the present perforation pattern of the prescribed inventioneliminates the possibility resealing when exposed to highertemperatures. Spaced in approximately 1.25″ square perforations, thelow-emittance housewrap material achieves a preferred permeance andwater vapor transmission of approximately 7 perm or 40 g/day/m². Assuch, the present low-emittance housewrap material performs within theoptimal permeance and water vapor transmission range of about 5 to about20 perm.

The present low-emittance housewrap material meets the StandardSpecification for Reflective Insulation, C 1224-03, Section 6, 6.1,which states that “Low emittance materials shall have a surface with anemittance of 0.10 or less, in accordance with test Method C 1371.”Specifically, the present low-emittance housewrap material achieves anemittance of 0.10 or less, more specifically within a range of about0.03 to about 0.05, in accordance with test Method C 1371.

Accordingly, the product low-emittance housewrap material of the presentinvention is constructed to include the following approximateperformance characteristics:

Test Description Test Results Perm Test 7 perms ASTM E-96 Water AsReceived 23 hrs Resistance Pass ASTM D-779 Weathered 23 hrs PassUltraviolet light No Cracking Accelerated Aging No Cracking TensileStrength 23 lbs/inch (machine direction) 25 lbs/inch (cross direction)U-value .056 vinyl Wall (zone 5-7) 2010 IECC U-value .051 brick Wall(zone 5-7) 2010 IECC U-value .063 Stone Wall (zone 5-7) 2010 IECC

Although the use of 1/16″ punchers at a rate of four holes per 1.25square inch is described above and represents one of many preferredembodiments of the present invention, other size punchers may be usedand other rates of holes per given area are within the scope of thepresent invention. For example, the diameter of the puncher may bevaried to any suitable size and the rate may be modified to achieve theparticular permeance and emittance standards required by a particularbuilding code, specification or other requirement.

The system U-values described in The Evaluation of Thermal Resistance ofa Building Envelope Assembly demonstrates the performance of wood framedwalls (2×4 construction 16″ on center). The U-value calculations arebased on methods outlined by the ASHRAE Handbook of Fundamentals. TheU-value performance of these systems achieve a U-value between 0.051(brick), 0.056 (vinyl) and 0.063 (stone) satisfying or exceedingrequirements for zones 1-7 established by 2010 IECC Code Table 402.1.3or equivalent UA alternative values established by other code bodies.

Flap portion 16 is illustrated in FIG. 3. This overlapping flange servesas a self adhered drainage plane 24. During assembly of one or morelow-emittance housewrap sections, the flap portion 16 may be assembledto cover an edge of an abutting portion of another low-E housewrapmaterial section in order to seal the edge. For example, turning toFIGS. 4 and 5, a first section 10 of low-emittance housewrap material ispositioned near a second section 12 of low-emittance housewrap material.The flap portion 16 of the second section 12 of low-emittance housewrapmaterial may be disposed over an edge portion 38 of the first section 10of low-emittance housewrap material. In one embodiment, theaforementioned edge portion 38 may include an adhesive strip 18 forretaining the flap portion 16 thereon. The adhesive strip 18 may beemployed on the top surface 20 such as on the reflective foil material34. While the adhesive strip 18 has been described and shown in thedrawings for illustrative purposes, any means may be employed which issuitable for retaining the flap portion 14 over the edge portion 38 inorder to provide a water resistive barrier between the abutting sectionsof low-emittance housewrap materials.

Turning to FIGS. 6 and 7, a protective film is removed to expose theadhesive strip 18 in preparation for securing the flap portion 16 overthe edge portion 38. The flap portion 16 is contacted to the adhesivestrip 18 and secured over the edge portion as illustrated in FIG. 8.This assembly serves to provide a water resistive barrier between twoabutting sections of low-emittance housewrap materials of the presentinvention to effectively seal their respective edges and allow waterrunoff from one low-emittance housewrap material section to anotherlow-emittance housewrap material section.

A bottom view vantage point of abutting low-emittance housewrapmaterials is illustrated in FIGS. 9-10. Again, the first section 10 oflow-emittance housewrap material is positioned near the second section12 of low-emittance housewrap material. The flap portion 16 of thesecond section 12 of low-emittance housewrap material is disposed overan edge portion 38 of the first section 10 of low-emittance housewrapmaterial. Edge portion 38 may include an adhesive strip 18 for retainingthe flap portion 16 thereon. As a sufficient force is applied, forexample, to flap portion 16 to contact the adhesive strip 18, the flapportion 16 is held in retention over the edge portion 38 as shown, forexample, in FIG. 11. It is clear from FIG. 11 that, in a final assemblyarrangement, a foam edge portion 56 of a first low-emittance housewrapmaterial 10 abuts a foam edge portion 58 of a second low-emittancehousewrap 12. Accordingly, the assembled sections serve to provide awater resistive barrier between two abutting sections of low-emittancehousewrap materials of the present invention.

In order to improve the energy efficiency of new and existing buildingstructures, application of the herein described low-emittance housewrapserves to cover the exterior wall sheathing with an infiltrationbarrier, for example, prior to installation of a covering material orexterior finish such as siding, brick, stone, masonry, stucco andconcrete veneers, for examples. The herein described low-emittancehousewrap also serves to protect against air infiltration and damagingmoisture build-up. Air infiltration may occur in typical constructionthrough, among other places, sheathing seams and cracks around windowsand doors. Moisture build-up can occur externally in the wall cavityfrom, for example, leaking exterior finishes or coverings, and cracksaround windows and doors. The low-emittance housewrap of the presentinvention does not trap the water, but rather allows it to flow downwardso as to exit the wall system.

Installation procedures of the presently described low-emittancehousewrap include those as described, for example, in the technicalmanual for ESP Low-E® Housewrap utilized on exterior walls and under aprimary barrier. The technical manual for ESP Low-E® Housewrap issubmitted herewith and is hereby fully incorporated herein by reference.Turning to FIG. 12, an exemplary exterior wall assembly 40 isconstructed and prepared for receiving the low-emittance housewrapmaterial of the present invention. In the illustrated example, a windowopening 42 is shown. In a preferred embodiment, the low-emittancehousewrap is employed after the walls have been construction and allsheathing and flashing details have been installed. The low-emittancehousewrap material is preferably applied before doors and windows havebeen set inside framed openings and prior to the installation of theprimary wall covering.

Turning to FIG. 13, a first low-emittance housewrap material is appliedto the wall assembly 40. The reflective side of the low-emittancehousewrap material is installed facing outwardly. In one preferredembodiment, a roll of low-emittance housewrap material is unrolledhorizontally starting at the corner of a preferred exterior wall 40. Theflange side or flap portion (e.g., 14, 16 of FIG. 1) of the roll isinstalled facing downwardly. The low-emittance housewrap material issecured to the exterior wall with fasteners 48 such as staples or capnails (or any other suitable fasteners) at preferably every 8-12″. Whenapplying another horizontal run of low-emittance housewrap material 44,the foam ends of each applied section of rolled low-E housewrap materialabut together such that the flange 52 of the additionally appliedlow-emittance housewrap material 44 is allowed to overlap the outsideedge 50 of the adjacent low-emittance housewrap material 46. Thisinstallation ensures that any intruding water is encouraged by thedrainage plane (e.g., 24 of FIG. 2) to flow downwardly.

In a preferred embodiment, the flange 52 is installed to overlap theabutting foam edge by approximately 2″. The low-emittance housewrapmaterial is installed to extend over all of the sill plates by a minimumof approximately 1″. The vertical and horizontal seam areas are sealedwith suitable low-emittance foil tape. The low-emittance housewrapmaterial may be trimmed around each framed opening with additionalappropriate detailing applied as per window/door manufacturer and/orcode standards.

Once installed, an appropriate exterior covering may beapplied/installed over the low-emittance housewrap. Such covering mayinclude, but not limited to, siding, brick, stone, masonry, stucco andconcrete veneers. The utilization of the herein described low-emittancehousewrap provides, inter alia, a protective wrap that not only improvesenergy efficiency in accordance with newly implemented industry-wideenergy/code regulations, but enhances drainage of damaging moisturebuild-up while protecting against air infiltration.

Moreover, other implementations of the invention will be apparent tothose skilled in the art from consideration of the specification andpractice of the invention disclosed herein. Various aspects and/orcomponents of the described embodiments may be used singly or in anycombination. It is intended that the specification and examples beconsidered as exemplary only, with a true scope and spirit of theinvention being indicated by the following claims.

1-25. (canceled)
 26. A flexible insulation for use in an insulationsystem comprising: a base insulating material; a substrate materialhaving a first side and a second side; a covering material positionedover the substrate material, wherein the base insulating materialprovides a system U-value less than 0.063; and a plurality ofperforations opening through both the base insulating material and thecovering material; wherein the plurality of perforations provide theflexible insulation with a permeance and water vapor transmission over 5perm.
 27. The flexible insulation of claim 26, wherein the perforationsare provided in the flexible insulation at a rate of four holes per 1.25square inch.
 28. The flexible insulation of claim 26, wherein theperforations are provided in rows, and wherein at least one perforationin one row of perforations is offset from another perforation in anotherrow of perforations.
 29. The flexible insulation of claim 26, whereinthe perforations are generated from a perforation system consisting of1/16″ punchers.
 30. The flexible insulation of claim 26, wherein theperforations are provided in a repeating pattern.
 31. The flexibleinsulation of claim 26, wherein the flexible insulation is alow-emittance material.
 32. The flexible insulation of claim 26, whereinthe base insulating material comprises closed cell polyethylene foam.33. The flexible insulation of claim 26, wherein the base insulatingmaterial comprises polyolefin material.
 34. The flexible insulation ofclaim 26, wherein the base insulating material has a thickness ofbetween 0.125″ and 0.375″.
 35. The flexible insulation of claim 26,wherein the substrate material comprises a scrim reinforcing material.36. The flexible insulation of claim 35, wherein the scrim reinforcingmaterial provides the flexible insulation with a tensile strength ofapproximately 23 pounds per inch width in a machine direction and 25pounds per inch width in a cross machine direction on a test specimenmade of the flexible insulation, wherein the test specimen has a size ofapproximately 1″ wide by 9″ long.
 37. The flexible insulation of claim26, wherein the covering material comprises aluminum.
 38. The flexibleinsulation of claim 26, wherein the substrate material and the coveringmaterial extend beyond an edge of the base insulating material to form aflap.
 39. The flexible insulation of claim 38, wherein the flap is aself adhered drainage plane.
 40. The flexible insulation of claim 26,wherein the adhesive material is provided in a strip along an edge ofthe flexible insulation and is provided on a surface of the coveringmaterial.
 41. The flexible insulation of claim 26, further comprising asecond covering material positioned over a back side of the baseinsulating material.
 42. The flexible insulation of claim 26, whereinthe flexible insulation achieves an emittance of 0.10 or less inaccordance with test Method C
 1371. 43. The flexible insulation of claim26, wherein the covering material is reflective.
 44. A flexibleinsulation comprising: a base insulating material; a reinforcementmaterial having a first side and a second side; a covering materialpositioned over the reinforcement material, wherein the first side ofthe reinforcement material and the base insulating material are coupledwithout use of an adhesive and wherein the second side of thereinforcement material and the covering material are coupled without useof an adhesive, wherein the base insulating material provides a systemU-value less than 0.063; a plurality of perforations, wherein each ofthe perforations comprises an opening through both the base insulatingmaterial and the covering material; and wherein the plurality ofperforations provide the flexible insulation with a permeance and watervapor transmission in a range of about 5 to about 20 perm.
 45. A highreflectance insulating material comprising: a base insulating material,wherein the base insulating material comprises closed cell polyethylenefoam or polyolefin, wherein the base insulating material provides asystem U-value less than 0.063; a strengthening layer on the baseinsulating material; a covering material positioned on the supportmaterial, the covering material including a reflective facing, thestrengthening layer reinforcing the covering material; a plurality ofperforations, wherein each of the perforations comprises an openingthrough both the base insulating material and the covering material; andwherein the plurality of perforations provide the insulating materialwith a permeance and water vapor transmission over 5 perm.
 46. A methodof fabricating a high thermal resistance and high permeance insulationmaterial comprising: providing a base insulating material; applying astrengthening layer having a first side and a second side on the baseinsulating material; applying a covering material positioned over thesecond side of the strengthening layer, wherein the base insulatingmaterial provides a system U-value less than 0.063; and creating aplurality of perforations opening through both the base insulatingmaterial and the covering material sufficient to provide the insulationmaterial with a permeance and water vapor transmission over 5 perm. 47.A method of installing insulation material between an exterior wall anda primary barrier comprising: constructing an exterior wall assembly;applying an insulation material to the exterior wall assembly, theinsulation material including a base insulating material, astrengthening layer, a covering material positioned over thestrengthening layer, wherein the base insulating material provides asystem U-value less than 0.063; and a plurality of perforations openingthrough both the base insulating material and the covering material,wherein the plurality of perforations provide the flexible insulationwith a permeance and water vapor transmission over 5 perm; securing theinsulation material to the exterior wall assembly; and applying anexterior covering over the insulation material.